Smart electrical switch with audio capability

ABSTRACT

In one embodiment the present disclosure relates to providing wireless speaker functionality in an electrical switch assembly, such as a light switch located in the wall of a building. The switch assembly includes a faceplate with a touch-sensitive speaker grille covering a sizeable portion of the faceplate. The disclosed designs enables the grille portion of the faceplate to provide sound transmission and electrical switch control, thereby allows for a larger speaker to be placed centrally in the junction box, while maintaining full electrical switch functionality. In some embodiments illumination components (e.g. electroluminescent regions) are arranged on a circuit board with a plurality of openings designed to align with the grille. The illumination components can illuminate regions of the faceplate, indicating the current state of one or more electrical switches

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of patent application Ser. No.14/788,726, filed on Jun. 30, 2015 by the present inventor.

This application claims the benefit of provisional patent applicationSer. No. 62/054,389, filed on Sep. 24, 2014 by the present inventor.

REFERENCES

The following is a tabulation of some prior art that presently appearsrelevant:

U.S. Patents

Patent Number Kind Code Issue Date Patentee 5,914,826 A 1999 Jun. 22Smallwood 6,091,037 A 2000 Jul. 18 Bachschmid 3,927,402 A 1975 Dec. 16Thompson 8,675,887 B2 2014 Mar. 18 Yuan et al. 8,666,104 B2 2014 Mar. 4Ivey et al. 7,608,948 B2 2009 Oct. 27 Nearhoof et al. 7,299,892 B2 2007Nov. 27 Radu et al.

U.S. Patent Application Publications

Publication Nr. Kind Code Publ. Date Applicant 20050237218 A1 2005 Oct.27 Tang et al. 20140270237 A1 2014 Sep. 18 Wang et al 20140270264 A12014 Sep. 18 Wang et. al 20110181201 A1 2011 Jul. 28 Hollis 20070289860A1 2007 Dec. 20 Newman et al. 20060161270 A1 2006 Jul. 20 Luskin et al.

TECHNICAL FIELD

The present disclosure relates generally to systems and methods forcombining audio capability and user controls on the grille portion of aspeaker. In particular the technology relates to a building-basedelectrical switch having an audio speaker, whereby a portion of theswitch faceplate comprises a speaker grille speaker that provides meansfor both sound transmission and electrical switching.

BACKGROUND

The proliferation of consumer wireless electronics (e.g. smartphones,tablet PCs and laptops) has resulted in consumers increasingly carryingmusic collections with them. Speaker manufacturers have responded tothis market trend by making smaller, more portable wireless speakers andwireless multi-room speakers (e.g., Bluetooth portable speakers andmulti-room Wi-Fi speakers). As the form factor of wireless speakersshrinks, the area available for user input controls (e.g. Volume, Play,Pause) has also decreased. In a related area smart home electronics arebecoming more popular. It would be advantageous to incorporate a speakerinto new implementations of traditional devices (e.g. electricalswitches, Thermostats and door locks). Providing adequate music-qualitysound in a small enclosure is difficult, in part because speakerstypically requires a large volume of space in a device enclosure. Thespace required to transmit sound form a speaker in a smart home device(e.g. a thermostat or light switch) competes for available space withthe legacy control functions of traditional home control devices(e.g.electrical switches and Buttons and keypads, door-bells and lightfixtures). For example the size and shape of household electricaljunction boxes has remained largely unchanged since the 1940's. Abuilding based, wall-mounted electrical switch (e.g. light switch)typically comprises of three parts: a junction box located on or withinthe wall, one or more switches mounted inside the junction box (e.g.paddle and button types) and a faceplate to cover the switches. Thejunction box has one or more bays to accommodate one or more switches.Each bay is approximately 2 inches wide and 4 inches high, therefore a2-bay box would be 4 inches wide and could accommodate two standardlight switches. When a house is constructed, the size of each junctionbox is typically selected to implement the lighting design. There aretypically no unused or empty bays in junction boxes. This practice of“right-sizing” junction boxes is in part because unused bays must becovered for safety purposes and the presence of nonfunctioning extrabays with blank cover plates can be confusing to users. Recent trends insmart home appliances (e.g. wirelessly enabled lights and switches) makethese prewired electrical junction boxes attractive location for newfunctionality. The practice of selecting the size of junction boxes tofit the original electrical requirements (e.g. lighting requirements andthe need for switch-activated electrical outlets) is problematic to thetask of adding additional functionality within junction boxes inexisting homes. An ongoing challenge is how to increase thefunctionality within household electrical boxes while maintain theoriginal functionality, which is often to provide electrical switching(e.g. light switches).

U.S. Pat. No. 5,914,826 disclose a speaker placed beside a light switchin a two-bay junction box. The speaker occupies one bay of the junctionbox. One disadvantages of this approach is that it reduces thefunctionality of the junction box by 1 switch. Another disadvantage isthat this speaker-switch combination cannot be implemented in asingle-bay junction box. U.S. Pat. No. 6,091,037 discloses a morecompact speaker-switch combination but still requires a 2-bay junctionbox. Means of implementing these designs in a 1-bay box is notdisclosed. This is an important limitation since the light switch inmany rooms is located in a single-bay junction box. Importantly U.S.Pat. No. 7,608,948, U.S. Pat. No. 5,914,826 and U.S. Pat. No. 6,091,037do not provide means to effectively combine the functions of soundtransmission and electrical switching. In conclusion, insofar as I amaware, no electrical switch assembly previously disclosed has provided abuilt-in speaker while maintaining the functionality of all availableswitching bays in the junction box. Similarly, no electrical switchassembly has combined both a speaker and a lighting switch in asingle-bay configuration. Similarly, no electrical switch assembly hasprovided a faceplate that effectively combines sound transmission andelectrical switching.

SUMMARY

In one aspect of the present disclosure an interactive speaker faceplatewith a touch sensitive grille area is disclosed. Methods to implementtouch sensitivity on a speaker grille are provided while promotingeffective sound transmission from a speaker behind the interactivegrille.

In one embodiment a building-based electrical switch assembly (e.g. alight switch) in a wall-mounted junction box includes a speaker and aninteractive speaker grille. The speaker grille has a several distincttouch-sensitive regions and fulfills the legacy functionality of one ormore electrical switches. The design enables a bigger speaker to becentrally located in the junction box, for enhanced music quality, whilemaintaining all of the functionality of the electrical switch. Thefaceplate can be located similarly to a traditional light switchfaceplate. The faceplate covers the transition from the wall to thejunction box. The faceplate of the present system can also have aplurality of openings forming a speaker grille for the speaker. Theopenings extend over the center region of the faceplate to provideprotection for the speaker cone behind, while allowing sound vibrationsto be emitted from the speaker.

In some embodiments of this disclosure the faceplate and speaker grilleare made from electrically insulating material and fulfills a designrequirement to electrically insulating the user from high voltage wiresand components associated with the electrical switch assembly. Thespeaker grille region provides the functionality of one or moreelectrical switches. Sensors disposed behind the speaker grille sensedirect user interaction with several regions of the faceplate. Sensorssignals are used to operate low voltage switches (e.g. touch sensitiveswitches). Low voltage switches can be combined with high voltageswitches (e.g. relays and triacs) to implement the electrical switchingfunctionality of a standard electrical switch, while much of the volumeinside the electrical junction box is devoted to housing a speaker.

In one aspect of the disclosure, the grille section of the faceplate hasa plurality of touch-sensitive regions enabled by touch sensors behindthe front insulating faceplate. One or more of the touch sensors canalso provide control over aspects of the speaker. In another aspect ofthe disclosure touch sensitive electrodes can be disposed on a substratebehind the grille, wherein the substrate has a plurality of opening thatalign with the grille, thereby providing touch sensitive functionalityto the grille while maintaining the sound quality from the speaker andproviding electrical insulation.

The disclosed designs enable the faceplate to act as both a grille forthe speaker and as one or more electrical switches and thereby allowsfor a larger speaker to be placed centrally in the junction box, whilemaintaining full electrical switch functionality. This in turn allowsthe user to control the electrical switches and experience improvedsound quality. In other embodiments illumination components are arrangedon a circuit board with a plurality of openings aligning with thegrille. The illumination components (e.g. electroluminescent regions)can light regions of the faceplate, indicating the current state of oneor more electrical switches ((e.g. ON/OFF or degree of dimming) In thismanner the speaker grille can act as an interactive control panel whilenot diminishing sound quality.

In some embodiments the speaker grille enables the system to detect whena person is proximal to the switch and activate an aspect of the speakeror switch. In one embodiment the speaker grille is an insulatingmaterial with conductive features deposited on the interior surface toenable person detection. In other embodiments elements deposited on theinterior surface of the faceplate enable indication of the state of theswitch. The techniques described in this specification can beimplemented to achieve the following exemplary advantages:

Improved sound quality from an electrical switch by centrally locating aspeaker where the switch typically resides. The system can beretrofitted in a building-based electrical junction box that is fullyutilized without loss of any of the electrical load switchingfunctionality. For example, previously a 2-bay junction box couldaccommodate a 2-inch wide speaker and a single 2-inch wide switch,thereby diminishing the functionality of the junction box by one switchwhile only allowing allow the speaker to occupy half of the junctionbox. With the present system both bays (4 inch by 4 inch) can be devotedto the speaker and the electrical switches can be implemented using thetouch-sensitive speaker grille. The speaker can provide audio feedbackwhen the switch is actuated, thereby providing the user with a familiar“click” sound associated with actuating a mechanical switch. Theelectrical switch with audio functionality can function as a wirelessspeaker for example a Bluetooth speaker offered to a hotel guest, whilethe location of the speaker is ensured by the placement of the speakerin the wall and power is supplied continuously from the electricaljunction box.

A plurality of regions of the grille can illuminate in response to auser touching the faceplate and grille portion and can guide the user tocorrectly operate the switch or to indicate the current position of aswitch or dimmer switch. Still further advantages will become apparentfrom a study of the following description and the accompanying drawings.

DRAWINGS

FIG. 1 is an exemplary diagram of the front faceplate of an electricalswitch assembly with audio capability and means for a user to operatetwo switches in accordance with an aspect of the present disclosure.

FIGS. 2A and 2B is a disassembled view of an electrical switch assemblywith audio capability, including a speaker, and a touch sensitivefaceplate in accordance with an embodiment of the present invention.

FIG. 3 is a block diagram illustrating various components of anelectrical switch assembly with audio capability in accordance with oneembodiment of the present technology.

FIGS. 4A and 4B illustrates an exemplary front view of a faceplate witha touch sensitive speaker grille and two circuit boards in accordancewith one embodiment of the present technology.

FIGS. 5A to 5C. illustrates a finger interacting with a target sensorelectrode and a neighboring sensor electrode in accordance with oneembodiment of the present technology.

FIG. 6 illustrates an insulating electrical substrate with conductiveelectrodes designed in accordance with one embodiment of the presenttechnology.

FIG. 7 illustrates various elements of an indicator light assemblyincluding insulating electrical substrate with light emitting elementsin accordance with one embodiment of the present technology.

FIGS. 8A and 8B illustrate exemplary front views of a faceplate with aspeaker grille operable to sense direct user interaction in accordancewith one embodiment of the present technology.

FIG. 9 illustrates an exemplary rear view of a faceplate with a touchsensitive speaker grille in accordance with one embodiment of thepresent technology.

FIG. 10 illustrates is a disassembled view of an interactive speakergrille in accordance with an embodiment of the present invention.

FIG. 11 illustrates exemplary front views of a faceplate with a speakergrille and solid center section in accordance with one embodiment of thepresent technology.

FIG. 12 is a flow chart diagram that outlines the operation of anelectrical switch assembly with audio capability in accordance with anaspect of the present disclosure.

FIG. 13 is a flow chart diagram that outlines the operation of anelectrical switch assembly with audio capability and illuminated switchindication in accordance with an aspect of the present disclosure.

FIG. 14 is a flow chart diagram that outlines the operation of aninteractive speaker grille with audio capability and illuminated grilleregions in accordance with an aspect of the present disclosure.

FIG. 15 is a flow chart diagram that outlines the operations associatedwith integrating an electrical switch assembly with audio capability,including a touch sensitive speaker grille.

DETAILED DESCRIPTION—FIG. 1-FIG. 11

In the following detailed description, for purposes of explanation,numerous specific details are set forth to provide a thoroughunderstanding of the various implementations of the present invention.Those of ordinary skill in the art will realize that these variousimplementations of the present invention are illustrative only and arenot intended to be limiting in any way. Other implementations of thepresent invention will readily suggest themselves to such skilledpersons having the benefit of this disclosure.

In addition, for clarity purposes, not all of the routine features ofthe implementations described herein are shown or described. One ofordinary skill in the art would readily appreciate that in thedevelopment of any such actual implementation, numerousimplementation-specific decisions may be required to achieve specificdesign objectives. These design objectives will vary from oneimplementation to another and from one developer to another. Moreover,it will be appreciated that such a development effort might be complexand time-consuming but would nevertheless be a routine engineeringundertaking for those of ordinary skill in the art having the benefit ofthis disclosure.

It is to be appreciated that while one or more implementations aredescribed further herein in the context of a typical building basedelectrical switch assembly used in a residential home, such assingle-family residential home, the scope of the present teachings isnot so limited. More generally, electrical switches with audiocapability according to one or more of the preferred implementations areapplicable for a wide variety of buildings having one or more speakersincluding, without limitation, duplexes, townhomes, multi-unit apartmentbuildings, hotels, retail stores, office buildings and industrialbuildings. Further it is to be appreciated that an electrical switchwith audio capability according to the implementations disclosed couldbe implemented in ships and airplanes. Further, it is to be appreciatedthat while the terms user, customer, installer, homeowner, occupant,guest, tenant, landlord, repair person, and the like may be used torefer to the person or persons who are interacting with the speaker orother device or user interface in the context of one or more scenariosdescribed herein, these references are by no means to be considered aslimiting the scope of the present teachings with respect to the personor persons who are performing such actions.

FIG. 1 is a diagram illustrating the front view of an exemplarywall-mounted electrical switch assembly 100 in accordance with anembodiment of the present disclosure. The electrical switch assembly 100is designed to reside in an electrical junction box (not shown in FIG.1). FIG. 1 illustrates a 2-bay switch assembly. A touch sensitivefaceplate 105 controls power to two wires 110 a and 110 b and therebycontrols the operation of two lights 115 a and 115 b. Alternativeimplementations of this disclosure can include other sizes of electricalswitch assembly optimized for different sizes of electrical junction boxdesigned to serve different numbers of building-based electrical devices(e.g. Lights, switch operated electrical outlets or garbage disposals).For example, a single bay junction box is common in many bedrooms toaccommodate a single light switch, while other locations may have threeor four bay junction boxes. Faceplate 105 contains a plurality ofopenings 120 that form a speaker grille 114. A substantial portion ofthe faceplate 105 can be occupied by speaker grille 114 (e.g. 50-100% ofthe total area of the front surface of faceplate 105). Grille 114protects a speaker (not shown in FIG. 1) located behind the faceplatewhile enabling effective sound transmission through the openings 120.The faceplate, and in particular speaker grille 114, is touch-sensitive,thereby enabling a person 125 to touch portions of the speaker grille114 to operate lights 115 a and 115 b. Speaker grille 114 combines avariety of functions including sound transmission, light switch control,speaker protection and user protection. Aspects of the presentdisclosure show how to implement touch sensor functionality, whileproviding sound transmission through a large number of openings in thegrille 114. The touch sensitive speaker grille 114 and faceplate 105 canregister binary user commands (e.g. ON/OFF) as well as continuum userinput commands (e.g. increase illumination with a dimmer). Elements 130a, 130 b and 130 c are regions of the faceplate that illuminate in orderto further facilitate a user 125 with visual feedback. For exampleelements 130 a and 130 b can show the present state of the electricalswitches number 1 and number 2 (e.g. ON/OFF/dimmed). In oneimplementation elements 130 a and 130 b are two elongated lines of lightindicating the position of two dimmer switches. The user 125 can touchthe faceplate 105 and drag the illuminated indication regions 130 a and130 b up or down to a desired location and controlling lights 115 in theprocess. Faceplate 105 designed in accordance with the presentdisclosure provides means for visual switch position indication andtouch sensitive surfaces while facilitating sound transmission with alarge speaker grille portion 114. In some implementations the touchsensitive speaker grille 114 can provide improved access for sensorspositioned behind the faceplate (e.g. passive Infrared, active infraredproximity sensors or temperature sensors) to measure the environment inthe region in front of the faceplate 105. In some implementationssensors located behind the touch-sensitive speaker grille can provideenhanced sensing of a person in the vicinity of the switch assembly andilluminate regions 130 a, 130 b and 130 c when a person is nearby. Inthe implementation illustrated in FIG. 1 electrical switch assembly 100,receives wireless signals 135 and can play music or audio messages froma variety of wireless devices 140, for example a smartphone 140 a, atablet PC 140 b or a media server 140 c. The media server 140 c can bean internet gateway (e.g. a home broadband internet router) and transmitinternet radio content to electrical switch assembly 100.

FIGS. 2A and 2B are disassembled views of an electrical switch assemblyincluding a speaker grille 214 that can sense direct user interaction(e.g. touch or pressure) in accordance with one implementation of thepresent disclosure. Switch assembly 100 contains a housing 210. Housing210 is a mechanical enclosure for components of electrical switchassembly 100. In one implementation housing 210 provides electrical andmechanical separation for components in electrical switch assembly 100from the contents (e.g. wires) in an electrical junction box 215.Housing 210 can contain two or more electrical terminals 290 operable tobe attached to building-based wiring. Building based wiring can includewiring within the walls of a building or carried in metallic or plastictubing for the purpose of electrically connecting switches and servicepoints in the building. Service points can include wall mountedelectrical sockets, HVAC equipment, sprinkler components and lightingfixtures in ceilings and walls. Examples of terminals 290 include screwterminal (e.g. those found on many light switches) and wire pigtails(e.g. a length of wire protruding from the housing). Housing 210 may besized to fit in an electrical junction box 215 of a particular size. Forexample the two-bay junction box illustrated in FIG. 1 is approximately4 inches wide and can accommodate two standard electrical lightswitches. The exemplary housing 210 in FIG. 1 is approximately 4 incheswide and 4 inches high and is designed to fit inside the majority oftwo-bay electrical junction boxes. Housing 210 has forward facingsurfaces 217 a and 217 b.

Housing 210 contains a speaker 205 operable to generate sound in theregion of the assembly. Speaker 205 functions to emit sound through thegrille portion 214 of faceplate 105. Grille 214 and grille 114 areoperable similar exemplary grilles with different shapes. Speaker 205can be an electromagnetic type speaker with an external or internalelectromagnet. In FIG. 2A speaker 205 is located centrally in housing210 and can occupy the position traditionally occupied by one or moremechanical switches. In another aspect of several embodiments thespeaker grille is designed to fulfill the function of the electricalswitches, including dimmer switches, that would traditionally occupy thespace where speaker 205 is placed. Speaker 205 can have mountingfeatures securing it to the housing 210 and in some embodiments anair-tight seal is be formed between speaker 205 and housing 210 thatenables further audio quality enhancement. Speaker 205 can have amounting flange 206 operable to secure the speaker to housing 210.Mounting flange 206 can have a variety of shapes including square orcircular. Speaker 205 has a speaker cone 207 operable to move in thepositive and negative Z direction when the electromagnet in the speakeris energized. The cone has a forward facing surface operable to projectsound in the Z direction. In one embodiment the electrical switchassembly is designed to fit inside a 1-bay electrical junction box withdimensions of approximately 2 inches in the Y direction of FIG. 2A and 4inches in the direction of X in FIG. 2B. In this embodiment the assembly100 could contain a 3 W 4 ohm speaker with a speaker cone with adiameter of approximately 50 mm. In another embodiment the electricalswitch assembly 100 is designed to fit inside a 2-bay electricaljunction box with dimensions of approximately 4 inches in the Ydirection of FIG. 2A and 4 inches in the positive X direction in FIG.2B. In this embodiment assembly 100 can contain a larger speaker with acone of diameter 76 mm. Speaker 205 could be model number 1-530-767-12from Sony. Speaker 205 can have a similar design to the speakercomponent used in a portable Bluetooth or Wi-Fi enabled wirelessspeaker, for example Jawbone Jambox®. In some embodiments electricalswitch assembly 100 can include two or more speakers. This is sometimesadvantageous when more sound volume is required than can be provided bya single speaker.

Electrical switch assembly 100 can contain a faceplate 105 with a frontsurface including portions 212 a and 212 b. The front surface caninclude a large portion 212 a in the X-Y plane and can also include theedges of the faceplate 212 b. The front surface including portions 212 aand 212 b provide surface for the user to interact while at the sametime faceplate 105 provides electrical isolation, between the user andhigh voltage components in the switch assembly behind the faceplate.Faceplate 105 can be constructed from a variety of materials includingplastics, glass or enamel covered metal or metal. Faceplate 105 can beflat with rounded edges as illustrated in FIG. 2A and FIG. 2B. In otherembodiments faceplate 105 can have a curved structure that can provideincreased mechanical stiffness, when the front of the faceplate istouched or pressed. Faceplate 105 can contain one or more ribs molded onthe interior surfaces to further increase mechanical stiffness.Faceplate 105 can function to conceal the gaps between the enclosure 210and the electrical junction box 215. The faceplate provides anaesthetically pleasing front surface for the user to interact with whileconcealing gaps between paint or drywall interfaces and junction box215. FIG. 2B illustrates that faceplate 105 contains a plurality ofopenings 120 that form a speaker grille portion 214 of the faceplate.Openings 120 can have a variety of shapes including circular, diamond,or oval. Speaker grille 214 is designed to transmit sound into the airspace in front of the faceplate in a manner so as to provide effectivesound to a user in the vicinity of the electrical switch assembly. FIG.11 illustrates that speaker grille can be disposed as a complex shapecomprising a plurality of openings 120 surround one or more solidsections 1110. A solid section 1110 could be a decorative surface for amanufacturer to place a logo, hold a button, hold a touch sensitivebutton or an illuminated element. In the context of this disclosure aspeaker grille refers to a portion of the faceplate 105 comprising aplurality of openings operable to transmit sound from a speaker andwould not include the solid section 1110 illustrated in FIG. 11. In someembodiment the grille comprises several small clusters of openings. Inthis case the grille can refer to the combined portions of the faceplatecovered by the openings. In the absence of molded features, edges ormaterial differences delineating the boundary of the speaker grille 214portion of faceplate 105, the grille portion can considered to bebounded by straight lines joining the points on the perimeter of thoseopenings that form the perimeter of a plurality of openings. Faceplate105 contains one or more regions 240 wherein direct user input (e.g.,touching, swiping or pressing) is operable to be sensed by one or moresensor electrodes 255. For example regions 240 a, 240 b and 240 c inFIG. 2A are exemplary touch sensitive regions used to control theoperation of two electrical switches. In one implementation user inputregion 240 a functions as a binary switch to turn off switch number 2.While the exact mechanism for turning off switch number 2 in response todirect user input is detailed later, it can be appreciated that regions240 are operable to initiate the process of controlling one or moreelectrical switches. For example the region 240 c is operable to receivedirect user input and direct user input sensors 330 (in FIG. 3) behindthe faceplate can initiate the turn on of switch number 2. In anotherexample a user input region 240 b of the faceplate 105 can function toact as analog switch, capable of controlling light 115 a to have a valuewithin a range of switch values (e.g. from 0 to 100). Examples of analogswitches include slider actuators, dimmer switches, rotary dialswitches. Physical features on the faceplate can indicate the intendedfunction of a region. For example in FIG. 2B switch number 1 and switchnumber 2 can be separated by a molded feature 225 delineating theboundary between the two switches on the common faceplate. Features 225can also be deposited on the faceplate using other technologiesincluding printing, etching, painting, overlay or electroplating. Userinput regions can control a function that is variable and dynamicallydefined by a computer processor. Region 240 d illustrate an example of aregion that could initiate a plurality of control functions in a speakerapplication for example changing the volume, selecting a song, playingor pausing music or selecting an input source. In one implementation thefunction of 240 d can be defined by the direction or gesture the usermakes while touching the region. For example swiping up and down maycontrol light switch functionality, while swiping from left to right maydecrease sound volume of the speaker and right to left may increasesound volume. The differentiation of these functions can be provided bythe sequence of sensors 330 (in FIG. 3) activated behind the frontsurface of region 240 d. The function of region 240 d can be based inpart the prior sequence of regions 240 that the user has interactedwith. Illuminated sections of the faceplate 130 can indicate the presentfunctionality of region 240 d.

In the embodiment illustrated in FIG. 2B speaker grille 214 occupies alarge portion of the faceplate 105. In this context a large portion canrange from 30-100% of the faceplate area. In one aspect of thisdisclosure user input regions 240 overlap with grille 214. In someembodiments user input regions can be fully contained within the grilleportion of the faceplate. Speaker grilles are common on most speakers,where they provide mechanical protection for the sensitive speakercomponents while providing a path for sound vibrations to be emitted.

Electrical switch faceplates are required to provide electricalinsulation between a user and high voltage components (e.g. wires)inside the junction box. In one aspect of the present disclosureelectrical switch assembly 100 has a speaker grille 214 made from anelectrically insulating material, for example plastic, glass, glassfilled plastic, or ceramic. In one embodiment shown in FIG. 2A and FIG.2B the grille and the surrounding area of the faceplate are made fromthe same piece of plastic, with the grille comprising a plurality ofopenings 120 covering the center section of the faceplate. In otherembodiments the grille may be different material from the rest offaceplate, for example a plastic grille with an insulated metallicfaceplate. The openings can be a wide variety of shapes (e.g. circular,square or elongated slots). A speaker grille is a combination ofopenings 120 and solid portions between the openings. The arrangement ofopenings and solid portions often forms a pattern and enhances theaesthetic appeal of the speaker enclosure. The combination of openings120 and solid support material is designed to achieve competing goals ofblocking or filtering objects larger than the grille openings whileenabling air and sound waves to pass through the grille. The grille isnot a perfect sound transmitter. The solid portions of the grilleattenuate or diminish several physical properties such as soundintensity, light intensity and air flow. Sound attenuation can be causedby sound reflected back towards the speaker as it attempts to passthrough the grille.

FIG. 2A illustrates a circuit board 260 behind the faceplate 105 andplaced in front of the speaker 205. The circuit board has an insulatingsubstrate 262 that functions to hold conductors 254 and sensorelectrodes 255 operable to sense direct user input. Conductors 254 canfunction to carry signals to and from sensor electrodes and can have alarge ratio of length to width (e.g. >100). Modern circuit boardmanufacturing technologies such as photolithography and foil etching canproduce conductor features 254 as narrow as 40 micrometers. Electrodesare operable to sense an aspect of a user (e.g., capacitive orresistance changes associated with a user touching the front surface offaceplate 105. Electrodes can have a larger surface are and smalleraspect ratio than conductors on the same circuit board. Circuit board260 has a plurality of openings (e.g. 220 a and 220 b). Openings 220 aand 220 b function to enable sound from the speaker 205 to pass throughthe substrate. Openings 220 are designed to align with openings 120 inthe faceplate so as to not to add to the overall sound attenuation andreflection of the grille. In one implementation opening 220 a is largerthan the corresponding opening 120 a in the faceplate and can be largeenough to cover multiple holes in the front faceplate. In oneimplementation 220 a can be larger than the opening 120 a in the speakergrille. For example openings 220 a could be a slot encompassing twoopenings in the faceplate. In some embodiments circuit board 260 can bea rigid circuit board made from layers of fiberglass and epoxy withdeposited conductors. In other implementations circuit board 260 is aflexible circuit board. The faceplate 105 with speaker grille 214 can becombined with one or more circuit boards 260 to form an interactivegrille. The interactive grille enables the switch assembly to transmitsound while accomplishing the task of switch power to household items.The switching functionality is accomplished by splitting the switchingtask into two functions sensing and power switching. The interactivegrille enables the sensing to take place on the sound transmittinggrille while the power switching is accomplished by circuitry locatedaway from the path of sound transmission. Examples of circuitry locatedaway from the path of sound transmission include low voltage switchesand high voltage switches located behind the speaker in enclosure 210.One high voltage switch 280 is illustrated behind the speaker in FIG.2A. In the context of this disclosure high voltage refers to voltageswith magnitudes greater than 20 volts. Low voltage refers to voltageswith magnitudes in the range 0-20 volts. Examples of high voltageswitches include electromechanical relays, solid state relays andtriacs. A triac is a fast solid state switch often used to implementdimmer switches in buildings. Grille 214 can be larger than the speakercone 207 extend beyond the speaker in the X-Y plane, thereby providingthe benefits of access to the surrounding air to additional sensors inthe electrical switch assembly. The speaker cone 207 is defined by theinside perimeter of speaker flange 206. For example a microphone 268could be placed in the housing and behind the grille, whereby theinteractive grille provides improved sound coupling and thereforeimproved sound sensing in the vicinity of switch assembly 100.Similarly, a passive infrared sensor 269 can be placed behind theinteractive grille to sense motion in the vicinity of the speaker.Openings in the grille provide enhanced motion sensitivity. In otherembodiment some or all of the sensor electrodes 255 can be depositeddirectly onto the rear surface of the speaker grille usingelectroplating or conductive inks. It would be known to someone skilledin the art that conductors and electrodes can be deposited on3-dimensional polymer parts using modern technologies such as LaserDirect Structuring (LDS) or Molded Interconnect Device MID technology.

Mounting features 256 on the housing 210 can be connected tocorresponding mounting features 222 on the electrical junction box 215.For example 256 can be an oblong opening in the housing 210 and feature222 can be a threaded hole. A screw could be used to connect 256 and222. This arrangement enables fine adjustment of the orientation of thehousing. In some embodiments additional mounting features 257 a-d areoperable to secure faceplate 105 to the housing 210. In severalembodiments mounting features 257 a-d are load sensors. This enables thefaceplate to be attached to the housing in a manner enables the loadsensors 257 a-d to generate sensor signals when the faceplate is touchedor pressed. For example mounting features 257 a-d could be planar beamtype load sensors such as those available from Omega Engineering INC,Stamford Connecticut. In some embodiments there may more or less loadsensors than the four shown in FIG. 2A. In response to a user touchingor swiping an area of the faceplate the timing and sequence of loadsensors values can be used to determine the area touched and the motionpathway (e.g., swipe in the up direction or down direction)

FIG. 3 is a block diagram of an exemplary electrical switch assembly100, illustrating electrical components used to provide the twofunctions of sound transmission and electrical switching in accordancewith one implementation of the disclosure. Wireless devices 140 cantransmit wireless signals 135 to the electrical switch assembly 100.Switch assembly 100 contains an antenna 305 to receive wireless signals135. Antenna 305 can be printed on a circuit board, a discrete stampedmetal component or an electroplated feature on a surface. In oneembodiment of the disclosure the antenna can be deposited or attached toa subassembly including faceplate 105. On advantage of attaching ordepositing the antenna on the faceplate is that placement of the antennaoutside of the metal junction box can improve the antenna range andsensitivity. The antenna is operably coupled to a wireless receiver 306.Receiver 306 can be operable to receive and demodulate a variety ofcommon wireless audio protocols such as amplitude modulated (AM) orfrequency modulated (FM) radio signals (e.g. 88.9-107.7 MHz), Bluetooth,Wi-Fi or Apple Airplay®. Receiver 306 can be part of a transceivermodule that also includes transmission capability. Receiver 306transmits demodulated wireless messages 307 to a speaker processor 308.The speaker process performs operations to convert the digital wirelessmessages into audio frequencies. These operations can includedigital-to-analog conversion, amplification, equalization, errorcorrection, echo cancellation, bass enhancement, or introducing a delayto one or more frequency components. Speaker process 308 and wirelessreceiver 306 can be integrated into a single module or microchip. Forexample a Bluetooth wireless speaker can have a single chip receiver andspeaker processor. Electrical switch assembly 100 can include an audioamplifier 309. Amplifier 309 operates to receive audio signals from thespeaker processor, to increase the power of these signals and totransmit amplified audio signals 316 to the speaker 205. Amplifier 309can be a single chip amplifier or can comprise multiple discretetransistors. Amplifier 309 can be a class A, B, A/B C or D amplifier.Amplifier 309 transmits amplified signals to the speaker. Amplifier 309can be for a PAM1803 Class D audio amplifier available from Diode INC,Plano Tex. The amplifier 309, speaker processor 308, and receiver 306can be housed behind the speaker, away from the path of soundtransmission.

Electrical switch assembly 100 contains a plurality of direct user inputsensors 310. Direct user input sensors operate to sense direct userinteraction with user input regions 240 of the faceplate 105. Examplesof direct user interaction include touching or pressing the faceplate.Examples of direct user input sensors include sensor electrodes 255, 605a, 605 b (shown in FIG. 6) and a load sensors 257 a-d. Other examples ofa direct user input sensor could be a membrane switch such as found onmany modern appliances such as a washing machine or stove control panel.Direct user input sensors 310 can operate to sense direct user inputbased on a variety of standard technologies. Examples of direct userinput technology are capacitive touch sensing, resistive touch sensing,surface acoustic wave touch sensing and pressure sensing. In surfaceacoustic touch sensing a surface acoustic wave is generated on the frontsurface of the faceplate by one or more transmitters. Aspects of thereflected signals (e.g. arrival time and intensity) are used to sense auser touching the faceplate surface. In response to direct user input,sensors 310 generate direct sensor signals 311 a. Direct sensor signals311 a can be current, voltage, frequency or sound intensity changesassociated with user input sensed by one or more direct user inputsensors 310. In some embodiments an electrical connector 315 providestwo separable halves that enable electrical connections to be madebetween conductors 254 and one or more low voltage switches 320. Onehalf of electrical connector 315 may be disposed on a circuit board 260and the other side may be disposed inside the housing 210. When a personattaches circuit board 260 to the housing 210 electrical connector 315can connect electrical signals between conductors 254 and circuitry inthe housing.

In one embodiment of the present disclosure, electrical switch assembly100 provides the two functions of sound transmission and electrical loadcontrol using touch sensitive switches. In this embodiment the grille214 is a touch sensitive surface while the other circuitry required toaccomplish electrical switching function is positioned away from thesound transmission path of one or more centrally located speakers. Theexemplary electrical switch assembly 100 illustrated in FIG. 3 containsa low voltage switches 320. Other implementations may contain multiplelow voltage switches. The switch can be located in housing 210. Theswitch can function to convert sensor signals 311 a and 311 b into lowvoltage switch output signals 322. Low voltage switch 320 can comprise amicrochip or microcontroller. Many modern microcontrollers can havededicated circuitry designed to implement low voltage touch sensitiveswitches. For example the Texas Instruments MSP430 processor from andthe MicroChip DSPic33 processor families have analog-to-digitalcircuitry operable to implement the functionality of the low voltageswitch 320. In some embodiments this circuitry enables conversion ofdirect user interaction with a surface (e.g. touching or pressing) intolow voltage switch output signals 322. In some embodiments sensorsignals 311 can cause small changes in in the frequency of anoscillating circuit inside the low voltage switch 320. The processor isoperable to measure these frequency changes and control one or more lowvoltage switch output signals 322 based on frequency changes. This typeof frequency measurement is often used to transduce sensor signals fromcapacitive touch sensors. Several electrodes can be sequentiallyconnected to a frequency measurement circuit inside low voltage switch320 and switch 320 can identify when the user touches one or more of alarge number (e.g. >50) of distinct regions on the faceplate 105. Inother embodiments the low voltage switch 320 can include ananalog-to-digital converter operable to sense small changes in voltagefrom sensors and generate digital values corresponding to the magnitudeof sensor signals 311. A processor in the low voltage switch 320 canhave a preset threshold for the change in magnitude or frequency thatwould correspond to a user touching the faceplate. When the low voltageswitch 320 measures a change in frequency or magnitude sufficient tocross this threshold the state of an output pin on the low voltageswitch can be changed. The change in state of the output pin can act asa low voltage switch output signal 322. In other embodiments low voltageswitch 320 can include one or more elements designed to increase theoutput power of a low voltage switch signal. This process is sometimescalled “buffering” and can be performed for the purpose of controllinghigh voltage switches 323. Examples of components that can performbuffering include power transistors and relays.

In some embodiments the low voltage switch 320 can accept a large numberof sensor inputs 311 and can produce a large number of low voltageswitch output signals 322, where a large number is for example fifty ormore. In this way the low voltage switch can transduce a plurality ofsensor inputs into distinct switch output signals. In some embodimentsthis circuitry enables conversion of direct human interaction with asurface (e.g. touching or pressing) into output voltage signals. Inother embodiments the low voltage switch can combine several sensorsignals 311 a and 311 b, perform one or more calculations using acomputer processor in the low voltage switch 320 and generate one ormore low voltage switch output signals 322. For example low voltageswitch 320 can receive a direct sensor signal 311 a when a user touchesthe multifunctional grille 214 and second sensor signal 311 b from amotion sensor 269 when a person moves in front of the grille openings.Low voltage switch 320 can contain a processor that can combine directsensor signals 311 a and indirect sensor signals 311 b and generate anoutput signal. In some embodiments the low voltage switch can performtiming calculations to determine when to generate an output signal. Forexample electrical switch assembly 100 can receive direct sensor signals311 a from the region 240 a of the faceplate operable to turn off alight 115 a. About the same time low voltage switch 320 and can receiveindirect sensor input 311 b indicating a person moving in the vicinityof the switch assembly 100. In response to 311 a and 311 b low voltageswitch 320 can delay the transition of signal 322 to an OFF state by afew seconds in order to provide light while the person leaves thevicinity. In the context of this disclosure an ON state can beconsidered as having a voltage with a magnitude that is greater than asizeable portion (e.g. >20%) of a power supply voltage (e.g. 5V) used tooperate a low voltage switch 320. In the context of this disclosure anOFF state can be considered as having a voltage with a magnitude that isless than a sizeable portion (e.g. <20%) of a power supply voltage usedto operate low voltage switch 320. The power supply voltage can bemeasured relative to a reference voltage supplied to the low voltageswitch, often defined as a ground voltage or 0V. Low voltage switch 320can include circuitry to operate one or more illumination components330. Illumination components 330 can be LEDs or electroluminescentsegments, incandescent bulbs or fluorescent bulbs. Illuminationcomponents 330 can be switch position indicator lights operable toindicate to a user the output state of one or more high voltage switches323 or low voltage switch output signals 322.

In other embodiments electrical switch assembly can include one or moreillumination components 330. Illumination components 330 can be operableto illuminate portions 130 of faceplate 105 and can be located on acircuit board located behind the front surface 212 of the faceplate.Connector 315 can also provide a junction for low voltage switch outputsignals 322 d from a low voltage switch 320 to illumination components330. Low voltage switch 320 can operate illumination components 330(e.g. switch position indicator lights) in response to sensor signals.For example in response to a user touching a region of the faceplate,low voltage switch 320 can operate illumination components 330 toilluminate sections of the faceplate 130 a and 130 b indicating thepresent state of each of two dimmer switches. In another example apassive infrared sensor (PIR) could sense a person in the vicinity ofelectrical switch assembly 100 and signal low voltage switch 320 toilluminate regions 130 a and 130 b of the faceplate corresponding to thepresent value of low voltage switch output signals 322 a and 322 b(indicating the dimmer output to switch number 1 and ON-OFF position ofswitch number 2 respectively).

Low voltage switch output signals 322 are operable to control highvoltage switches 323 and other aspects of the electrical switch assembly100. Low voltage switch output signals 322 can be voltages in the rangeof minus 20 volts to plus 20 volts relative to ground in the junctionbox, the neutral wire or a local ground reference voltage supplied toboth the low voltage switch 320 and the high voltage switch 323. In oneimplementation low voltage switch output signal 322 a is a pulse widthmodulated signal (PWM) containing a series of pulses. Pulses contain twoor more distinct voltage levels; a high state and a low state voltage.By varying the time proportions of high and low state voltage the PWMvoltage waveform voltage switch output signal 322 a can control thedimmer switch 323 a. Other low voltage switch output signals 322 b canoperate electromechanical relays 323 b. Signals 322 b can supply acurrent to an electromagnet inside relay 323 b, thereby creating a lowresistance connection between wires 110 b and 110 d. In this context aconnection with resistance <3 ohms can be considered a low resistanceconnection. Other low voltage switch output signals 322 c can betransmitted to the speaker circuitry. FIG. 3 illustrates low voltageswitch output signals 322 c transmitted to the speaker processor 308.For example illumination components 330 can be used to indicate thevolume of speaker 205 as an illuminated section 130 a on faceplate 105.Grille 214 can additionally provide an active region 240 d. In responseto user interaction with 240 d direct input sensors 330 can generatesensor signals 311 a and cause low voltage switch 320 to signal speakerprocessor 308 to change the volume of the speaker. In anotherimplementation low voltage switch output signal 322 b operates a solidstate relay, in which the moving parts of an electromagnetic relay arereplaced with power transistors.

Electrical switch assembly 100 can contain a variety of other componentsand circuits. For example switch assembly 100 can contain a rectifier ordiode rectifier to convert high voltages to low voltages, a battery topower the speaker or low voltage switches, particularly during a poweroutage to the building where the switch assembly is located. Electricalswitch assembly 100 can contain one or more visual displays operable tobe seen through faceplate 105. In some alternative embodiments amplifier309 can be contained within speaker processor 308. In other embodimentsspeaker processor 308 and low voltage switch 320 can be combined in ageneral purpose processor that combines the ability to sense user inputand generate sound signals using digital-to-analog conversion or pulsewidth modulation. An example of a processor that could combine thefunctionality of speaker processor 308 and low voltage switch 320 is theDSPic33 processor family from Microchip Incorporated. In one embodimentof electrical switch assembly 100, the functionality of one or moretouch sensitive regions 240 can be determined by the present state ofone or more low voltage switch output signals 322 a or 322 b. Forexample when a user walks into an room where the lights are OFF, lowvoltage electrical switch 320 can identify that one or more low voltageoutput signals 322 correspond to the light being in the OFF position andcan interpret signals 311 a from some or all touch regions 240 asindications to turn on the light. In this way the electrical switchassembly can identify direct user interaction and estimate theassociated intent based on the output state of one or more electricalswitches 323. When a person enters a dark room they often reach for thelight switch and use the tactile feel of the switch as user feedback. Inone example electrical switch assembly could devote sensor signals 311 afrom user interaction with some or all of the surface of the grille tothe function of turning on a light in this scenario, thereby alleviatingthe user from the burden of touching a particular ON location (e.g. 240c). In this example an indirect input sensor (e.g., a light leveldetector) located behind the speaker grille could supply sensor signals311 b to a low voltage switch 320, indicating the light level in theroom and enabling the low voltage switch to interpret sensor signals 311a from a larger number of direct user input sensors 310 as indication tooperate a high voltage switch to turn on a light. In another example,indirect user input sensors 325 (e.g. a PIR sensor or proximity sensor)could sense a person who has entered a dark room and illuminate one ormore regions 130 of faceplate 105. The indirect sensor can benefit fromplacement behind the grille 214 with a large density of openings 120that enhance motion signal intensity. In one aspect the electricalswitch assembly can illuminate features 130 with increasing intensity asperson gets closer to the faceplate (e.g. as they reach for the switch),thereby avoiding unnecessarily disturbing a person who is moving in thevicinity of the electrical switch assembly and does not intend tooperate an aspect of the assembly. Dynamic intensity variation can becontrolled in part by sensing a person with a plurality of differentsensing technologies. For example a faceplate can glow with a lowintensity when a person is sensed on a long range PIR sensor (e.g. with10 meter range). The faceplate can glow with a higher intensity if theperson is subsequently sensed by a shorter range proximity sensor (e.g.active infrared transceiver).

FIG. 4A illustrates several exemplary components of electrical switchassembly 100 designed to enhance audio performance while enablingelectrical switch functionality in according with embodiments of thisdisclosure. Two circuit boards 260 and 460 are positioned behind thefaceplate 105. Circuit board 260 contains a plurality of openings 220and circuit board 460 contains a plurality of openings 420. It can beappreciate that the density and shape of openings in the grille 214 canbe chosen to fulfill the competing goals of sound transmission andmechanical performance (e.g. electrical isolation and speakerprotection). By choosing the size and shape of openings 220 so as not tocover openings 120 with substrate material 262 the sound transmissionproperties of the faceplate 105 can be preserved. In particular byaligning one or more openings 220 and 420 with the grille openings 120the sound transmission performance becomes determined primarily byspeaker grille 214. In the context of this disclosure an opening 220 canbe considered to “align” with an opening 120 when the placement of 220is such that the area of the unobstructed opening formed by theoverlayed combination of 120 and 220 when viewed along an axis is atleast half the area of the corresponding opening 120. For example 220 aand 120 a are considered aligned in FIG. 2A because when assembled thearea of opening 120 a and the area of the opening when 120 a and 220 aare in an assembled state is essentially equal. Opening 220 a is madelarger than 120 a to ensure that any small misalignment of circuit board260 and faceplate 105 following assembly does not cause 220 a to impedesound transmission from speaker 205. In another example openings 120 band 220 b and are considered aligned when the electrical switch isassembled. By aligning one or more openings in the faceplate 105 andcircuit boards (e.g. 260 and 460) the present disclosure enables thecircuit boards to add functionality to the grille while transmittingsound from the speaker. For example circuit boards 260 and 460 canprovide mounting surfaces to hold touch sensor electrodes, indicatorlights, and environmental sensors such as a temperature sensor 480. Inone implementation a connector 315 is used to connect circuit board 460to one or more low voltage switches 320. In the context of thisdisclosure the improved sound transmission as a result of aligningopenings in the grille 214 and a circuit board can include, highervolume experienced in the region in front of the grille, decreasedreverberation caused by reflected sound from grille 214 and the circuitboard and improved audio clarity.

Circuit board 260 can be comprised of transparent conductors and atransparent substrate similar (e.g. clear plastic) to the touchscreenson tablet PCs. Transparent elements on circuit board 260 enable lightillumination components 330 (e.g. light emitting diodes 470 andelectroluminescent regions) on circuit board 460 to illuminate portions(e.g. sections 130) of the faceplate.

Conductive elements 255 can also be a transparent material such asindium tin oxide (ITO), antimony tin oxide or silver filled ink. In oneimplementation an interactive faceplate subassembly 485 is comprised ofthe faceplate 105 and circuit board 260. The interactive faceplatesubassembly 485 can be attached to the other components of theelectrical switch assembly by a user or installer. Interactive faceplatesubassembly 485 enables the alignment of one or more openings 120 andopenings 220 to be conducted in a controlled manufacturing environment.Interactive faceplate subassembly 485 further facilitates installationby enabling installation of other electrical switch assembly components(e.g., the speaker 205 and housing 210) into the junction box 215 priorto installation of the faceplate. This order of installation can help toavoid damaging sensitive sensor electrodes 255 in the interactivefaceplate subassembly 485. In another implementation interactivefaceplate subassembly 490 includes an additional circuit board 460operable to illuminate features on the faceplate. Connector 315 can bedisposed on a pigtail or a portion of flexible PCB designed tofacilitate connection between the two halves of the connector. Connector315 could be comprised of exposed connector electrodes at the end of aflexible PCB pigtail. Connector 315 can connect with a correspondingconnector in the housing 210, for example a zero insertion forceconnector (ZIF) such as those sold by TE Connectivity from HarrisburgPennsylvania. In other implementations interactive faceplate subassembly490 has plurality of connectors similar to 315. Using more than oneconnector 315 provides redundancy in case a connector pin becomes dirtyor damaged. One or more of the connectors can implement a safetyinterlock, thereby ensuring that portions of the electrical switchassembly 100 are not energized with high voltages until faceplatesubassembly is properly secured and the connector 315 is correctlymated. In one embodiment interactive faceplate subassembly 490 has fourconnectors similar to 315, with one located at each corner of thefaceplate to provide a means to both attach and provide power tosubassembly 490. Interactive faceplate subassembly 490 has severaladditional advantages. The subassembly can be provided in a variety ofcolors, shapes and sizes to fit aspects of the wall opening and theuser's preferences. Similarly, the size and pattern of grille member 214can be varied as well as the color of illuminated sections 130. Incontrast the portion of electrical switch assembly 100 inside thejunction box 215 can be standardized and offer less customization. FIG.4B illustrates a crossectional view of the speaker grille subassembly490 including aligned openings. Speaker 205 is shown for reference.

FIG. 5A and FIG. 5B illustrate the basic operating principle ofcapacitive sensing. A number of standard technologies can be adapted toprovide user input sensing in the presence of a large speaker 205 andpluralities of holes 120 220 and 420. These technologies includecapacitive touch sensing (illustrated in FIG. 5A and 5B), and resistivetouch sensing, surface acoustic wave touch sensing and load sensing. Afinger 505 is placed over a layer of insulating material 510. A targetelectrode 515 is disposed behind layer 510. Electrode 515 has abackground capacitive coupling to a ground electrode similar to 495.When a finger or other object directly interacts with the top surface oflayer 510 the capacitance 525 is often increased. The increase incapacitance causes a temporary current to flow in a conductor such as254 connecting the sensor electrode 255 to a low voltage switch 320.This current constitutes a direct sensor signal 311 a. FIG. 5B alsoillustrates an advantage of the present design. When a finger touches aconventional capacitive touch sensor, over a target electrode 515, asillustrated in FIG. 5A there is an unintended signal generated at aneighboring electrode 530. It is desirable to reduce thiscross-capacitance signal 535 a and 535 b. FIG. 5B illustrates acapacitive touch sensor in accordance with one implementation of thisdisclosure. There is an opening 540 in the insulating layer 510 betweenthe target and neighboring electrodes. This opening can be opening 120in the grille 214. This opening reduces the cross capacitance 535 bbetween the finger 505 and the neighboring electrode 530. By reducingthe undesirable cross-capacitance from 535 a to 535 b the presentdisclosure enables electrodes 515 and 530 to sense more accurately or beplaced closer together. In the present disclosure a plurality of holes120 in the faceplate 105 can cross-capacitance (C2<C1), thereby enablingimproved special resolution of touch identification. Yet anotheradvantage of the present assembly is illustrated in FIG. 5C whereby thetarget capacitance 530 can be increased by extending target electrode515 at least some of the way into opening 540. The extended section isillustrates as the shaded portion 517 of the target electrode in FIG.5C. One way to implement this electrode extension is to increase theplating thickness of electrode 515 close to opening 540. Electrode 515and 530 are examples of direct user input sensors 310.

FIG. 6 illustrates an exemplary electrode array designed to enable atouch sensitive speaker grille in accordance with one implementation ofthis disclosure. A variety of sensor electrodes including 255, 605 a and605 b are patterned on insulating substrate 262. Sensor electrodes areoperable to sense direct user interaction with a variety of regions 240of faceplate 105. The exact layout of sensor electrodes and regions 240will vary from one implementation to another. Electrode 255 is adiscrete sensor electrode designed to identify direct user interactionwith a binary input region of the speaker grille. 605 a and 605 b areelectrodes designed to nest within one another such that a user's fingeris sensed by 2 or more electrodes at most times. Region 610 includes 5nested electrodes and is used to implement a slider touch function. Whena user slides their finger up or down within the dimmer region 240 b ofthe faceplate 105 and grille 214, multiple electrodes in the touchslider electrode region 610 sense the direct user input and send sensorsignals 311 a to the low voltage switch 320. The low voltage switch caninterpolate the sensor signals and estimate the placement of the user'sfinger on the touch sensitive region of the faceplate and grille.Circuit board 260 includes a ground electrode 495 that acts as areference for the other electrodes. Circuit board 260 has a plurality ofopenings 220 places in accordance with aspects of this disclosure so asto enhance sound transmission. The size and location of openings 220 arechosen to align with openings 120. Conductors and electrodes can berouted around openings 220 as illustrated at 625. In some cases oneelectrode can be connected to multiple conductors 254. The conductorscan be routed in different paths around openings 220 to account for thepresence of plurality of openings 220. A person of skill in the artwould appreciate that a dense plurality of openings can be placed onsubstrate 260 and modern circuit board layout software is well suited torouting conductors and electrodes within the small portion of solidsubstrate 262 that can remain. Openings 420 and 220 can have a guardring 630 around the opening, whereby the guard ring is a ring around theopening without electrode material (e.g. copper foil). Guard ring 630can ensure that a user cannot see or touch the edge of an electrode.

FIG. 7 illustrates an exemplary circuit board 460 designed to illuminateregions 130 of the faceplate 105. Light can be generated on circuitboard 460 using a variety of technologies including light emittingdiodes (LEDs) or electroluminescenc (EL). In the embodiment illustratedin FIG. 7 two emitting diodes 470 are electrically connected between twoconductors 254 a and 254 b. Light emitting diodes 470 can beelectrically connected to circuit board 460 while enabling a pluralityof openings 420 to align with openings 120 in grille 214. In this mannerthe LEDs can be used to illuminate sections of the faceplate 105 whilethe circuit board 460 does not diminish the sound transmissionperformance of the electrical switch assembly.

Section 710 of circuit board encloses a region operable to produceillumination by a process of electroluminescence. Electroluminescentmaterials light up when current passes through them. A variety ofelectroluminescent paint kits are available for circuit boardapplications, for example the Luxprint® Electroluminescent products fromDupont. Conductors 254 c are deposited on substrate 460 to define theshape of the electroluminescent region. Conductors 254 c can have closeproximity (e.g. 100 micrometers) thereby enabling intricate conductorshapes to be illuminated. A dielectric layer 725 covers the conductors254 c. The dielectric layer has a high electrical resistance relative tothe underlying conductor 254 c. Dielectric layer 725 can comprise a highdielectric constant material such as barium titanate. The dielectriclayer can alternatively be a solder mask material deposited on thecircuit board 460. An electroluminescent material 730 covers thedielectric layer. Common electroluminescent materials include phosphorand zinc sulfide. One or more top electrodes 740 covers theelectroluminescent layer 730. In this embodiment the top electrode is atransparent electrode such as ITO on a clear plastic film. Alternatingvoltage applied to electrodes 740 and 254 c causes the overlappingregions of the electrodes 740 and 254 c to be illuminated. In someembodiments electrode 740 is large and covers a substantial portion ofthe circuit board 460. The electroluminescent region 710 can beparticularly useful for providing a user with visual feedback regardingthe state of one or more analog 322 a outputs from a low voltage switch320. For example region 710 can illuminate a dimmer switch position onthe faceplate, thereby guiding the user's finger to touch the region ofthe faceplate corresponding to the present dimmer location and raise orlower the light level by dragging their finger to a new location.Conductors 254 c can be closely spaced and can be energized in sequenceas the user moves their finger on the faceplate, thereby tracking theuser's finger with illumination from the original dimmer position to thenew dimmer level. Electroluminescence can produce complex lightpatterns, based on the shape of conductors 254 c. Electroluminescentilluminated regions 710 produce enhanced line edge definition incomparison to LED technology. Conductors 254 c can be patterned so as tocircumvent the openings 420. In this manner the electroluminescentregion 710 can be used to illuminate sections of the faceplate 105 whilethe circuit board 460 and openings 420 enhance the sound transmissionperformance of the speaker 205.

FIGS. 8A and 8B illustrate two additional embodiments of the faceplate105 of electrical switch assembly 100. In FIG. 8A molded features on thefaceplate can indicate touch sensitive areas of faceplate 105. Theraised areas can occupy a large portion of the faceplate. The size andshape of openings 120 can be designed to enhance sound performance andswitch functionality. In FIG. 8B a plurality of vertical slots 815 a aredisposed in a touch sensitive faceplate 105. The openings 815 a can bedesigned to produce a characteristic sound and sequence of direct userinput sensor signals 311 a electrode when a user moves their finger in avertical manner on the dimmer section of the touch sensitive faceplate105. In another example, a pattern of horizontal slots 815 b can bearranged to cover a sensor disposed behind the grille (e.g. a passiveinfrared sensor 269). In this case the openings can be optimized toprovide more openings with less space between openings in order toenhance sensitivity of PIR 269 to motion.

FIG. 9 illustrates an exemplary rear view of a faceplate with a touchsensitive speaker grille in accordance with one embodiment of thepresent technology. In this embodiment electrodes 255 and conductors 254are deposited directly onto the rear surface of the faceplate 105.Electrodes 255 and conductor 254 can be deposited using a variety oftechnologies including conductive ink or laser direct structuring LDS orselective plating. Electrodes 255 and conductors 254 are deposited on aninterior surface 910 of faceplate 105. Surface 910 contains a pluralityof openings 920 a and 920 b that align with openings 120 a and 120 b inthe front surface of the faceplate, and thereby enhance soundtransmission from a speaker that can be placed behind faceplate 105. Anelectronic component (e.g. an LED, thermistor or resistor) is attachedto the faceplate and electrically connected to conductors 954 a and 954b. This implementation enables one or more electronic components to bedisposed on the rear surface of the faceplate while not impeding soundtransmission from the speaker 205. One or more electronic components 930could be used with electrodes 255 to implement an indicator light thatis locally controlled by signals 311 a generated at touch electrodes 255and do not need to be processed by low voltage 320 in order to generateillumination control signals. Another advantage of the implementationillustrated in FIG. 9 is that alignment of the openings 120 in thefaceplate and openings 920 in touch electrode substrate can be enabledby a single molding operation. In particular, the step of aligning aseparate substrate (e.g., 260 in FIG. 2) is eliminated. Directstructuring technologies such as LDS are well suited to routing narrow(<100 micrometer) conductors 254 around a plurality of closely spacedopenings 920.

Other Embodiments

FIG. 10 illustrates an interactive speaker grille in accordance withseveral aspects of the present disclosure. Interactive speaker grille1005 is designed to transmit sound from a speaker 205, and containsportions that are touch sensitive and operable to illuminate distinctfeatures on the speaker grille. Interactive grille 1005 comprises afaceplate 105 and three circuit boards 260, 1060 and 460 located behindthe faceplate and in front of speaker 205.

Sound transmission is enhanced by aligning a plurality of openings onfaceplate 105 and circuit boards 260,460 and 1060. Faceplate 105 has aplurality of openings 120 that form a speaker grille 214. Whenassembled, opening 120 a aligns with openings 220 a 1020 a and 420 a andthereby promotes sound transmission from speaker 205 to the area infront of faceplate 105. It can be appreciated that a large number of theopenings comprising speaker grille 214 can be aligned with similaropenings on one or more circuit boards to promote sound transmission.The speaker grille 214 contains a plurality of regions 240 in whichdirect user interaction (e.g., touching or pressing) can be sensed by aplurality of electrodes 255 and 605 disposed behind faceplate. FIG. 10illustrate four exemplary regions 240 a, 240 b, 240 c and 240 d whereindirect user input is operable to be sensed by one or more sensorelectrodes 255, 605 a and 605 b on circuit board 260. For example directuse interaction (e.g., touching or pressing) with region 240 c causessensor electrode 255 to generate direct user input signals 311 a. Inanother example region 240 b of the faceplate 105 can function to asanalog switch. The placement position of a user's finger within region240 b indicates a desired user input value to a low voltage switch 320within a range of switch values (e.g. from 0 to 100). Region 240 d is anexample of a multipurpose touch sensitive region of speaker grille 214.Area 240 d can to control a variety of functions in a speakerapplication for example changing the volume, selecting a song, playingor pausing music or selecting an input source. The function of region240 d can be based in part the prior sequence of regions 240 that theuser has interacted with. Illuminated sections of the faceplate, forexample 130 c) can indicate the present functionality of region 240 d.Circuit board 260 contains a plurality of electrodes 255, and 605 boperable to sense direct user interaction with speaker grille 214.Electrodes 254 carry direct sensor signals 311 a to a low voltage switch320. Electrodes 254 are routed around the plurality of openings 220.

Sections of the interactive grille 1005 can be illuminated by lightgenerating components 470 (e.g. LEDs or organic LED) orelectroluminescent sections 710 (illustrated in FIG. 7). Lightgenerating components 470 and electroluminescent sections 710 can beplaced on a circuit board 260 with touch electrodes or can be placed onadditional circuit boards behind the touch sensor electrodes 255 and 605b. FIG. 10 illustrates an LED 470 on circuit board 460 and anelectroluminescent section (shown as 710 on FIG. 7). Theelectroluminescent section 710 contains the electrodes 254 c, dielectriclayer 725 and electroluminescent layer 730 described previously in thisdisclosure. In the implementation of FIG. 10 the top electrode 740 isreplaced by a plurality of electrodes 1010 disposed on a third circuitboard 1060. This arrangement enables horizontal electrodes 254 c andvertical electrode 1010 to be operated by signals 322 d (illustrated inFIG. 3) from a low voltage switch 320 and thereby generate anilluminated region 130 c on faceplate 105. Pixel 130 c on faceplate 105is above the region where the two electrodes cross. It can beappreciated that similar pixels of light can be generated at a largenumber of locations where a horizontal and vertical electrode pass overone another. It can be appreciated that the pixels can be disposedaround the plurality of openings 120 and can form a variety of patternsoperable to convey information to a user. In one implementation multipleilluminated pixels such as 130 c can display the function of amultipurpose active region 240 d for example displaying the volume ofthe speaker. In another example an array of pixels 1030 can display anequalizer, indicating the sound volume of particular frequency bands(e.g. 1000-2000 Hz). Such equalizer displays are common on multispeakermusic systems such as the Kenwood GE 100 and provide an aestheticappealing graphical display for the user. A plurality illuminatedregions 130 c can also generate patterns operable to change shape orintensity in time with the beat of a song. It would be understood by aperson of skill in the art that an array of pixels capable ofilluminating individual portions of the speaker grille 214, disposedaround a plurality of openings 420 a and 420 b can also be implementedby a plurality of discrete light emitting light elements 470, such asLEDs, organic LEDs, incandescent lamps or fluorescent lamps.

Electrodes 1010 can be made from a transparent material (e.g. indium tinoxide (ITO), antimony tin oxide (ATO) or silver ink) and thereby enhancelight transmission from electroluminescent layer 730 or discreteillumination devices 705. In FIG. 10 direct sensor signals 311 a aretransmitted to low voltage switch 320. Low voltage switch output signals322 d can be transmitted to electrodes 254 a and 254 b to controlillumination of light emitting elements 470. Light emitting elements 470are examples of illumination components 330 in FIG. 3. Other low voltageswitch output signals 322 d can be transmitted to electrodes 254 c and1010 to control illumination of some or all of electroluminescent region710 (illustrated in FIG. 7). In general a large number of low voltageswitch output signals 322 d can be used to operate a plurality ofilluminated components 330 (e.g. discrete light emitting elements 470 orelectroluminescent region 710) disposed around a plurality of soundtransmitting openings 420 a and 420 b, thereby illuminating sections 130of speaker grille 214. Direct sensor signals 311 a can also be used bylow voltage switch 320 to generate low voltage switch outputs 322 coperable to control aspects of a speaker processor 308. For example auser's finger can touch region 240 b of the interactive speaker grilleand cause sensors in slider region 610 (illustrated in FIG. 6) to sendsignals 311 to low voltage switch 320. The switch can in turn usesignals 311 a to generate low voltage switch output 322 c indicative ofthe position of the user's finger on the volume slider portion of thefaceplate. Speaker processor 308 can use signals 322 c to control themagnitude of signals 316 to the speaker 205. In one aspect of thepresent disclosure, low voltage switch 320 can also produce outputs 322d operable to control illumination of the section of the faceplatebehind 240 d thereby indicating to the user the volume control value. InFIG. 10 circuit board 260 and 1060 can be transparent and containtransparent conductors so as to facilitate illumination of distinctportions of the faceplate by illumination components 705 and 710 oncircuit board 460.

Interactive speaker grille 1005 can enable touch sensitive andilluminated regions of the speaker grille using one or more circuitboards disposed behind the grille have one or more openings that alignwith the openings forming the grille. FIG. 10 illustrates three circuitboards 260, 460 and 1060 in part to illustrate the arrangement ofcomponents (e.g. LEDs and electrodes) on individual substrates. It canbe appreciated the same touch sensing and illumination functionalitiescan be accomplished by combining the individual circuit boards 260, 460and 1060 into a variety of multiple-layer circuit boards. For examplecircuit boards 260 and 1060 can be two separate transparent circuitboards or can be combined into one transparent circuit board with touchelectrodes 605 a and 255 disposed on the surface facing the interactivegrille 214 and illumination electrodes 1010 disposed on the rear surfacefacing circuit board 460. Electroluminescent region 710 can requireintimate contact between electrodes 1010 and the electroluminescent(e.g., phosphor) layer 730. This contact can be accomplished by bondingcircuit board 1060 to board 460 in a manner similar to touch sensitivedisplay fabrication. One or more connectors similar to 315 can connectcircuit boards 260,460 and 1060. A connector can also be used to connectcircuit boards (e.g. 260 or 460) to another circuit board positionedbehind the X-Y plane formed by the flange 206 of the speaker 205.Electrodes on boards 260, 460 and 1060 can also be connected using wiresand solder contacts.

The interactive speaker grille 1005 enables a large area of the speakergrille 214 to be functionalized as a control surface and a displaysurface. In one aspect the speaker grille 214 can be made from anelectrically insulating material, thereby enabling the interactivespeaker grille to identify user interaction with multiple distinctregions of the grille. A dense plurality of openings 120 can facilitateeffect sound transmission. Interactive speaker grille 1005 can devote alarge region (e.g. region 240 d) to speaker controls. As wirelessspeakers have become more compact the surface area devoted to usercontrols has decreased. In contrast interactive speaker grille 1005could devote the whole grille area to controls such as radio stationselection, play, pause or skip to the next song. The touch sensitivecapability and the illumination functionality can be combined toimplement an interactive control. For example many of the speakers onthe market do not have enough available area to provide a volume sliderand therefore require the user to press a volume button multiple timesto increment or decrement volume. This repeated button pushing istedious and the user is often left without a visual indication of thevolume level. Illumination components 330 and low voltage output signals322 c can instead produce a visual pattern of illuminated sections 130 con the interactive speaker grille that effectively indicate the presentvolume level. A user can use a corresponding touch sensitive region(e.g. 240 c or 240 d) to initiate volume change. Touch functionality andilluminated components can be implemented on circuit boards with a denseplurality of openings arranged so as to enable sound impedance of theinteractive speaker grille 1005 in FIG. 10 is determined primarily bythe sound impedance of the grille member 214.

In another embodiment electrical switch assembly 100 can be used toreplace the functionality of a mechanical object (e.g., mechanicaltoggle switch) with which a user associates a characteristic sound(e.g., the “click” sound associated with a light switch or the chimeassociated with a doorbell). A speaker 205 disposed behind the touchsensitive speaker grille can produce the sound familiar to the user.This embodiment has the advantage that the user receives the sound fromthe area that is touches (i.e. the speaker grille) and not from anotherarea away from the touch sensitive surface, which would have thepotential to confuse a user. For example the electrical switch assembly100 could produce a familiar click sound when a user touches an area ofthe grille operable to control an electrical switch. In another examplethe touch sensitive speaker grille could be used to guide a persontowards a touch sensitive surface with audio feedback. For example aperson with visual impairment could follow sound emanating from thetouch sensitive speaker grille in order find the touch sensitive surfaceoperable to control aspects of the speaker or electrical switches. Thesound could vary to indicate that the user if getting closer or furtherfrom the interactive speaker grille.

Operation—FIG. 12-15

FIG. 12 is a block diagram illustrating the operation an electricalswitch assembly with audio capability in accordance with one embodimentof the present technology. At block 1210 the speaker 205 receives audiosignals 316 from amplifier 309. At block 1220 speaker 205 emits soundwaves through a pattern of openings in the speaker grille 214 and analigned pattern of openings in one or more circuit boards (e.g.,openings 220 in circuit board 260). At block 1230 a user touches aregion of the speaker grille portion 214 of the faceplate 105, whereinthe region is operable to be sensed by electrodes on circuit board 260or functionalized surface 910 disposed behind the front surface of thefaceplate. At block 1230 electrodes (e.g. 255, 605 a and 605 b) generatedirect sensor signals 311 a. At block 1240 sensor signals 311 a arereceived by one or more low voltage switches 320. At block 1240 the lowvoltage switch processes the signals; determine if the signals meetspecific criteria (e.g. touch location, duration, sequence). At block1250 electrical switch assembly 100 generates one or more low voltageswitch output signals 322 and transmits these signals to one or morehigh voltage switches (e g dimmer 323 a or relay 323 b). At bock 1260one or more high voltage switches 323 operate to control the connectionbetween one or more pairs building-based electrical wires. Thisoperating sequence enables the functionality of a traditional electricalswitch to be replicated using a combination of a low voltage switch anda high voltage switch, while devoting the space traditionally occupiedby the mechanical switch to a large speaker centrally disposed in theswitch housing and operable to project sound waves through a touchsensitive speaker grille.

FIG. 13 is a block diagram illustrating additional steps involved in theoperation of some alternative embodiments of the electrical switchassembly.

At block 1305 electrical switch assembly can receive wireless signals135 from a variety of wireless sources 140. System 100 can use awireless receiver 306, speaker processor 308 and amplifier 309 togenerate audio signals 316. At block 1325 electrical switch assembly 100can illuminate regions of the speaker grille using illuminationcomponents 330 disposed on a circuit board designed with a plurality ofaligned openings, wherein the opening promote sound transmission. Atblock 1327 electrical switch assembly 100 can optionally guide the userto an active region of the speaker grille using one or more illuminatedregions 130. At block 1345 illumination components 330 can be controlledusing low voltage switch output signals 322 d from the low voltageswitch processor 320.

FIG. 14 is a block diagram illustrating the operation an interactivespeaker grille 1005 in accordance with one embodiment of the presenttechnology. At block 1410 the speaker 205 receives audio signals 316from amplifier 309. At block 1420 speaker 205 emits sound waves througha plurality of openings in the speaker grille 214 and an alignedplurality of openings in one or more circuit boards (e.g., openings 220in circuit board 260). At block 1425 interactive speaker grille 1005 canilluminate regions of the speaker grille using illumination components330 disposed on a circuit board designed with a plurality of alignedopenings, wherein the openings promote sound transmission. At block 1430a user touches a region of the speaker grille 214, wherein the region isoperable to be sensed by direct user input sensors 310 (e.g. sensorelectrode 255) on circuit board 260 or functionalized surface 910disposed behind the front surface of the faceplate. At block 1427interactive speaker grille 1005 can optionally guide the user to anactive region of the speaker grille using one or more illuminatedregions 130. At block 1430 electrodes (e.g. 255, 605 a and 605 b)generate direct sensor signals 311 a. At block 1440 sensor signals 311 aare received by one or more low voltage switches 320. At block 1440 thelow voltage switch processes the signals; determine if the signals meetspecific criteria (e.g. touch location, duration, sequence). At block1445 illumination components 330 can be controlled using low voltageswitch output signals 322 d from the low voltage switch processor 320.At block 1450 a low voltage switch 320 generates one or more low voltageswitch output signals 322 c and transmits these signals to a speakerprocessor 308. At bock 1460 speaker processor 308 controls an aspect ofaudio signals 316 sent to speaker 205.

FIG. 15 is a block diagram outlining the operations associated withintegrating audio capability into an electrical switch assembly 100 inaccordance with several aspect of the present disclosure. At block 1510the integration can involve providing a housing 210 including a forwardfacing portion 217. At block 1520 the integration can involve providinga speaker 205 disposed inside the housing. At block 1530 the integrationcan involve providing a faceplate operable to be attached to the housingand to cover the speaker. At block 1540 the integration can involveproviding a grille portion of the faceplate having a first plurality ofopenings for sound generated by the speaker to be transmitted to theregion in front of the assembly. At block 1550 the integration caninvolve providing one or more sensors disposed behind the forward facingsurface of the faceplate and operable to sense direct user interactionwith one or more regions of the forward facing surface of the faceplate.At block 1560 the integration can involve incorporating a secondplurality of openings into the sensor substrate. At block 1570 theintegration can involve aligning at least one of the openings in thefirst and second plurality, so as to promote improved sound transmissionthrough the sensor substrate. At block 1580 the integration can involveproviding a low voltage switch operable to process direct sensor signalsfrom one or more of the sensors. At block 1580 the integration caninvolve providing sensor placement such that one or more of the sensorsare operable to sense direct user interaction with the grille portion ofthe faceplate.

1. An electronic sound generating system comprising: a housing; aspeaker located at least partially inside the housing; and aninteractive faceplate subassembly comprising: a front surface, wherein aportion of the front surface contains a first plurality of openingsforming a speaker grille; one or more direct user input sensors operableto sense direct user interaction with the front surface of theinteractive faceplate; wherein the one or more direct user input sensorsare disposed behind the front surface of the interactive faceplate on asecond surface with a second plurality of openings, and wherein at leastone of the openings in the second plurality of openings aligns with oneor more of the openings in the first plurality, thereby promotingimproved sound transmission from the speaker; and one or more regions onthe front surface of the faceplate wherein direct user interaction inthe one or more regions is sensed by at least one of the one or moredirect user input sensors, and wherein the one or more regions includesat least a portion of the speaker grille.
 2. The system of claim 1further comprising: one or more low voltage switches operable to receivedirect sensor signals from the one or more of the direct user inputsensors and wherein at least one of the low voltage switches generates alow voltage switch output signal in response to one or more direct usersensors sensing direct user interaction with the speaker grille.
 3. Thesound generating system of claim 1 wherein the speaker grille is furtherdefined as a region of the faceplate encompassing the first plurality ofopenings and wherein the region is bounded by a polygon, the polygoncomprising of straight line segments, wherein each straight line segmenttouches the perimeter of at least two of the openings in the firstplurality of openings.
 4. The sound generating system of claim 1 whereinthe one or more direct user input sensors are located on a circuitboard, wherein the circuit board is located behind the front surface ofthe faceplate, wherein the circuit board covers at least a portion ofthe speaker cone, and wherein the circuit board contains the secondplurality of opening.
 5. The sound generating system of claim 1 whereinthe direct user input sensors are based on a technology from a set oftechnologies including: capacitive touch sensing, resistive touchsensing, acoustic touch sensing, weight sensing and load sensing.
 6. Thesound generating system of claim 1 wherein the direct user input sensorsare sensor electrodes and wherein the sensor electrodes are formed on aninterior surface of the interactive faceplate subassembly using atechnology from a set of technologies including: screen printing, moldedinterconnect device technology, laser direct structuring, inkjetprinting, sputtering and electroplating.
 7. An electronic soundgenerating system with a touch sensitive speaker grille, the systemcomprising: a housing; a speaker located at least partially inside thehousing; a faceplate covering at least a portion of the speaker, thefaceplate comprising: a speaker grille having a first plurality ofopenings, wherein the speaker grille substantially protects the speaker,promotes sound transmission from the speaker and provides for physicalseparation between a user and the speaker; one or more direct user inputsensors that generate direct sensor signals; and one or more regions ofthe front surface of the faceplate wherein direct user interaction inthe one or more regions is sensed by at least one of the one or moredirect user input sensors, and wherein the one or more regions includesat least a portion of the speaker grille.
 8. The sound generating systemof claim 7 wherein the one or more direct user input sensors are locatedin front of the speaker cone on a second surface, wherein the secondsurface contains a second plurality of openings and wherein at least oneof the openings in the second plurality aligns with an opening in thefirst plurality of openings, thereby improving sound transmission fromthe sound generating system.
 9. The sound generating system of claim 7further comprising: one or more low-voltage switches operable togenerate one or more low voltage switch output signals, and wherein atleast one of the low voltage switches is operable to generate a lowvoltage switch output signal in response to direct user interaction withat least a portion of the speaker grille.
 10. The sound generatingsystem of claim 7 further comprising: one or more circuit boardsdisposed behind the front surface of the faceplate and having a portioncovering at least some of the speaker cone, wherein the one or moreprinted circuit boards contains a second plurality of openings, whereinat least one of the openings in the second plurality align with anopening in the first plurality of openings, thereby improving soundtransmission from the sound generating system, and wherein at least oneof the direct user input sensors is located on the portion of one of thecircuit boards that covers the speaker cone.
 11. The sound generatingsystem of claim 7 wherein the sound generating system is a portablespeaker system with a wireless receiver and the sound generating systemfurther comprises: one or more low-voltage switches operable to generateat least one low voltage switch output signal based at least in part onsensing direct user interaction with the speaker grille and wherein thelow voltage switch output signal operates an aspect of the portablespeaker system.
 12. The sound generating system of claim 7 wherein afirst non-zero subset of the direct user input sensors is operable tosense direct user interaction with a first region of the speaker grilleand wherein a second non-zero subset of the direct user input sensorsare operable to sense direct user interaction with a second region ofthe speaker grille and wherein the direct user interaction sensors inthe first subset and second subset are mutually exclusive.
 13. The soundgenerating system of claim 10 further comprising: one or moreillumination components disposed on at least one of the circuit boards;wherein the one or more illumination components are operable toilluminate one or more second regions of the faceplate, and wherein theone or more second regions includes at least a portion of the speakergrille.
 14. The sound generating system of claim 7 wherein in theassembled state the number of openings from the first plurality ofopenings that align with openings from the second plurality of openings,is at least
 50. 15. The sound generating system of claim 7 wherein thespeaker grille and the faceplate are comprised of one or morenon-metallic materials from a set of materials including: plastic,glass, glass-filled plastic or ceramic.
 16. The sound generating systemof claim 7 further comprising: one or more indirect input sensorsoperable to sense an aspect of the environment in the vicinity of thesound generating system and wherein the indirect sensor is disposedbehind the front surface of the grille and wherein the openings in thegrille facilitate the indirect input sensor to sense in the vicinity ofthe of the sound generating system.
 17. A method of integrating aninteractive speaker grille into a sound generating system comprising:providing a speaker; providing a faceplate operable to cover at leastsome of the speaker, wherein the faceplate includes a front surface;providing a speaker grille portion of the faceplate having a firstplurality of openings; providing one or more circuit boards, wherein theone or more circuit boards contain a second plurality of openings;positioning at least one of the circuit boards behind the front surfaceof the faceplate wherein at least one of the openings in the secondplurality of openings aligns with one or more of the openings in thefirst plurality of openings, thereby promoting improved soundtransmission from the speaker; providing a plurality of electroniccomponents disposed on the one or more circuit boards, wherein at leastone of the electronic components is encompassed by the second pluralityof openings; and generating with at least some of the plurality ofelectronic components an interactive property in one or more regions ofthe front surface of the faceplate and wherein at least one of theregions includes at least some of the speaker grille.
 18. The method ofclaim 17 wherein the generated interactive property is from a set ofinteractive properties including touch sensitivity and illumination ofone or more of the regions.
 19. The method of claim 17 wherein theplurality of electronic components comprises a plurality of illuminationcomponents encompassed by the second plurality of openings and whereinthe interactive property is illumination of a plurality of distinctregions of the speaker grille.
 20. The method of claim 19 furthercomprising: transmitting a plurality of low voltage switch outputsignals to the plurality of illumination components, illuminating atleast some of the plurality of illumination components based on theplurality of low voltage switch output signals and wherein the lowvoltage switch output signals are based at least in part on an aspect ofaudio signals sent to the speaker.